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1989 Kawasaki Mojave 250 Rebuild

I don’t have any before pictures of this 1989 250 Mojave rebuild project, but when I started this quad, I had to clean a mouse nest out of the air box and the plastic was junk.

ATV disassembled frame

Here is the bare frame after disassembly.

repainted ATV frame

Frame with new paint and rebuilt front A-arms, spindles and steering stem with handle bars added.

rear swing arm ATV repaint

Rear swing arm with rebuilt carrier bearing assembly.

rear swing arm with kawasaki green paint

Also used new All Balls pivot bearings. Kawasaki Green is a cool color.

tires on atv frame repainted

And we quickly came to this point in the project:

maxxis razr atv tires on repainted frame

I added some Maxxis Razr ATV tires mounted on ITP T9 Pro Wheels, a new Dura Blue Axle and Moose shock covers. Then I had to test fit the new Super Trapp Exhaust.

atv repaint reassembly

Coming along pretty nicely.

rebuilt engine on ATV

The rebuilt engine, rear fenders, seat and gas tank are all installed. Almost ready for test fire!

first start up of rebuilt ATV

First startup. It sounded pretty good with the new Super Trapp Exhaust system and engine modifications.

ATV kawasaki mojave repaint and rebuild

After adding a DG front bumper and grab bar, she’s ready to go.

first rebuild ride

We were happy with her maiden voyage.

friend on his rebuilt kawasaki mojave 250

Here is the proud owner before he tore it up a few times. The first thing to go were those cool lights that I put on the hood. 

TJ (Tire Jockey)

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